What is a Catalyst Carrier?
A catalyst carrier (also called catalyst support) is a high-surface-area material that provides mechanical strength, thermal stability, and dispersion for the active catalytic metals (Pt, Pd, Ni, Mo, Co, etc.). The carrier itself is typically catalytically inert but contributes acidic sites and textural properties that influence catalyst performance.
For industrial catalysis, alumina-based carriers are the most widely used because of their unique combination of properties: high surface area (150-380 m²/g for gamma form), tunable pore structure, mechanical strength, chemical inertness, and low cost. Carrier shape also matters: spherical carriers offer low pressure drop, trilobe and extrudate shapes provide higher geometric surface area, and macroporous microspheres enable diffusion-limited reactions.
Our Catalyst Carrier Product Line
As a leading Chinese manufacturer with 15+ years of experience, Zibo Yingchuan Aluminum Co., Ltd. supplies six standard shapes of high-purity alumina catalyst carriers. Each shape is engineered for specific reactor types and process conditions.
1. Catalyst Carrier Ball
Spherical catalyst carriers manufactured by oil-drop method for uniform shape, smooth surface, and excellent mechanical strength. Used in moving bed and ebullated bed reactors where low attrition is critical.
- Size range: 1-3 mm, 3-5 mm, 5-8 mm, 8-10 mm (custom available)
- Al₂O₃ content: ≥96% (γ-alumina) or ≥99% (α-alumina)
- Surface area: 180-280 m²/g (γ) or 5-10 m²/g (α)
- Crush strength: ≥80 N/bead (3mm), ≥150 N/bead (5mm)
- Applications: Reforming catalyst support, ebullating-bed hydrocracking, fixed-bed hydrotreating, moving-bed catalyst
2. Trilobe Shape Catalyst Carrier
Three-lobed extrudate shape providing 30-40% higher geometric surface area compared to standard cylinders, improving catalytic activity per unit reactor volume.
- Size: 1.5 mm, 2.0 mm, 3.0 mm (custom diameters)
- Al₂O₃ content: ≥95%
- Surface area: 200-300 m²/g
- Crush strength: ≥50 N/mm (axial)
- Applications: Hydrodesulfurization (HDS), hydrodenitrogenation (HDN), FCC catalyst additives, hydrocracking
3. Extrudate Shape Catalyst Carrier
Standard cylindrical extrudates — the most widely used shape due to cost-effectiveness and proven performance across refining processes.
- Size: 1.5 mm, 3 mm, 5 mm diameter (length 3-15 mm)
- Al₂O₃ content: ≥95%
- Surface area: 180-280 m²/g
- Pore volume: 0.4-0.7 cm³/g
- Applications: Hydrotreating, hydrocracking pre-treat, gas purification, Claus sulfur recovery
4. Five-Toothed Spherical Catalyst Carrier
Specialty shape combining the low pressure drop of spheres with enhanced surface area of multi-lobed designs. Reduces hot-spot formation in highly exothermic reactions.
- Size: 3-5 mm, 5-8 mm
- Al₂O₃ content: ≥96%
- Surface area: 200-280 m²/g
- Applications: Selective hydrogenation, fixed-bed oxidation, deep hydrodesulfurization
5. Ring Shape Catalyst Carrier
Hollow ring geometry dramatically reducing pressure drop in deep catalyst beds, ideal for fixed-bed reactors with high bed height.
- Size: OD 3-10 mm × ID 1-5 mm × Height 3-10 mm
- Al₂O₃ content: ≥95%
- Surface area: 150-250 m²/g
- Applications: Deep-bed hydroprocessing, gas drying towers, air separation prep beds
6. Macroporous Alumina Microspheres
High-purity alumina microspheres with engineered macropore structure (50-500 nm pore size) for diffusion-limited reactions and heavy-oil processing.
- Size: 0.5-1 mm, 1-2 mm, 2-3 mm
- Al₂O₃ content: ≥95%
- Pore size: 100-500 nm (macroporous)
- Surface area: 80-200 m²/g (with high pore volume 0.8-1.2 cm³/g)
- Applications: Heavy oil hydroprocessing, residue HDS, FCC catalyst support, ebullating-bed catalyst
7. Reforming Catalyst Support
High-purity spherical alumina specifically engineered as a support for catalytic reforming (Pt-Re, Pt-Sn) catalysts used in petroleum refineries to upgrade naphtha to high-octane gasoline.
- Size: 1.5-2.5 mm
- Al₂O₃: ≥99.5% (low impurities critical for noble metal catalysts)
- Surface area: 180-220 m²/g
- Na₂O: ≤0.02% (sodium poisons Pt sites)
- Applications: Continuous catalytic reforming (CCR), semi-regenerative reforming
8. Calcined Active α-Alumina Microspheres
Fully calcined alpha-alumina microspheres with very low surface area, used as inert bed support, diluent, or top layer in fixed-bed reactors to prevent maldistribution and hot spots.
- Size: 1-3 mm, 3-5 mm, 5-8 mm
- Al₂O₃: ≥99% (α-phase)
- Surface area: ≤10 m²/g
- Crush strength: ≥200 N/bead (5mm)
- Applications: Bed support, diluent for highly exothermic reactions, top layer for liquid distribution
Technical Specifications — Standard Grades
Gamma-Alumina (γ-Al₂O₃) Catalyst Carrier
| Parameter | GA-S (Standard) | GA-H (High SA) | GA-U (Ultra-High SA) |
|---|---|---|---|
| Al₂O₃ (%) | ≥96 | ≥95 | ≥94 |
| SiO₂ (%) | ≤0.05 | ≤0.05 | ≤0.05 |
| Fe₂O₃ (%) | ≤0.03 | ≤0.03 | ≤0.03 |
| Na₂O (%) | ≤0.10 | ≤0.10 | ≤0.10 |
| Surface Area (m²/g) | 180-220 | 250-300 | 320-380 |
| Pore Volume (cm³/g) | 0.4-0.5 | 0.5-0.7 | 0.7-1.0 |
| Bulk Density (g/cm³) | 0.7-0.8 | 0.6-0.7 | 0.5-0.6 |
| Crush Strength (N/bead, 3mm) | ≥80 | ≥60 | ≥40 |
| Attrition Loss (%) | ≤0.5 | ≤0.8 | ≤1.0 |
Alpha-Alumina (α-Al₂O₃) Inert Support
| Parameter | AA-S | AA-H (High Strength) |
|---|---|---|
| Al₂O₃ (%) | ≥99 | ≥99.5 |
| SiO₂ (%) | ≤0.05 | ≤0.03 |
| Fe₂O₃ (%) | ≤0.03 | ≤0.02 |
| Surface Area (m²/g) | ≤10 | ≤5 |
| Bulk Density (g/cm³) | 1.8-2.0 | 2.0-2.1 |
| Crush Strength (N/bead, 5mm) | ≥200 | ≥350 |
| Attrition Loss (%) | ≤0.2 | ≤0.1 |
Key Applications
- Petroleum Refining: Hydrodesulfurization (HDS), hydrodenitrogenation (HDN), hydrocracking (HC), catalytic cracking (FCC) — pseudoboehmite and gamma-alumina are the dominant carriers for Mo-Co, Mo-Ni, Ni-W catalysts
- Catalytic Reforming: Pt-Re and Pt-Sn reforming catalyst support for upgrading naphtha to high-octane gasoline
- Ebullating-Bed Hydrocracking: Macroporous microspheres with attrition resistance for residue HDS/HDN
- Automotive Catalysis: Three-way catalytic converter (TWC) washcoat, diesel oxidation catalyst (DOC), SCR catalyst support
- Petrochemical: Steam reforming, ethylene oxide, vinyl acetate catalyst support
- Claus Process: Sulfur recovery catalyst for natural gas processing and refinery off-gas
- Hydrogen Production: Reforming and water-gas shift catalyst supports for blue/green hydrogen
Why Choose Zibo Yingchuan Catalyst Carriers?
- 6 standard shapes + custom geometry — one supplier for all your catalyst carrier needs
- 15+ years export experience — trusted by catalyst manufacturers in 30+ countries
- Customizable specifications — surface area, pore size, PSD, crush strength, and chemical purity
- Low Na₂O grades available — ≤0.02% achievable for noble metal catalyst applications
- ISO 9001:2015 certified — batch-to-batch consistency CV < 5% for key parameters
- Free 1-2 kg sample — within 5 days for evaluation
Frequently Asked Questions
What shapes of catalyst carrier do you offer?
We manufacture six standard shapes: ball (1-10 mm diameter), trilobe (1.5-3 mm), extrudate (1.5-5 mm diameter), five-tooth spherical, ring (3-10 mm OD), and macroporous microspheres (0.5-3 mm). Each shape offers specific advantages: balls provide low pressure drop and uniform packing, trilobes offer higher geometric surface area, extrudates are cost-effective, rings minimize pressure drop in deep beds, and macroporous microspheres enable diffusion-limited reactions.
What is the difference between gamma and alpha alumina catalyst carriers?
Gamma-alumina (γ-Al₂O₃) is the transition form with high surface area (150-380 m²/g) used as a catalyst support for active metals. Alpha-alumina (α-Al₂O₃) is the thermodynamically stable form with very low surface area (<10 m²/g), used as an inert top layer, bed support, or diluent to prevent hot spots in catalyst beds. Most catalyst manufacturers use gamma-alumina for the active layer and alpha-alumina for support and dilution.
What is macroporous alumina used for?
Macroporous alumina microspheres (pore size >50 nm, often 100-500 nm) are used in applications where large molecules need to access the active sites, or where coke diffusion is a concern. Common applications: heavy oil hydroprocessing, residue hydrodesulfurization, fluid catalytic cracking (FCC) additives, and ebullating-bed catalyst supports. The large pores resist fouling and allow diffusion of high-molecular-weight hydrocarbons.
Can you customize catalyst carrier specifications?
Yes. We customize: (1) shape and size (any of the 6 standard shapes plus custom geometries), (2) chemical composition (Al₂O₃ content, SiO₂, Fe₂O₃, Na₂O limits), (3) physical properties (surface area 5-380 m²/g, pore volume 0.2-1.2 cm³/g, pore size distribution), (4) crush strength and attrition loss, (5) bulk density. Our R&D team works directly with your catalyst chemists to match carrier properties to your active metal recipe.
What is the minimum order quantity for catalyst carrier?
Standard shapes and grades: MOQ 500 kg. Custom shapes or specifications: MOQ 1-2 metric tons (to cover mold/tooling setup and trial production). Free 1-2 kg samples available for evaluation. Lead time: 7-15 days for standard grades, 25-40 days for custom specifications. We can also toll-process your pseudoboehmite into shaped carriers at our Zibo facility.